COURSE OVERVIEW:

Mechanical integrity (MI) auditing and compliance verification are essential for ensuring that pressure equipment, piping, and storage tanks are managed according to international codes and regulatory mandates. This course provides a comprehensive roadmap for auditing an MI program against the requirements of API 510, 570, 653, and the foundational ASME codes. Participants will learn how to move beyond simple checklists to conduct "deep-dive" technical audits that verify the effectiveness of inspection plans, the quality of NDT data, and the rigor of fitness-for-service assessments.

The scope of this training involves the evaluation of all elements of an MI system, including personnel competency, equipment documentation, and the management of inspection findings. Participants will explore the methodology for identifying "compliance gaps" between current site practices and the stringent requirements of the API codes and OSHA PSM (Process Safety Management) standards. The curriculum emphasizes the importance of a "traceable, verifiable, and complete" record for every asset, teaching attendees how to spot data inconsistencies that could lead to integrity failures or regulatory fines.

Detailed instruction is provided on the "Verification" phase, where auditors must confirm that field repairs and maintenance activities actually match the documented engineering specifications. The course covers the auditing of Risk-Based Inspection (RBI) programs, the verification of corrosion management strategies, and the assessment of "closing the loop" on inspection recommendations. By participating in mock audit exercises and reviewing real-world compliance findings, attendees will develop the skills necessary to lead MI audits that drive continuous improvement and ensure the long-term safety and reliability of industrial infrastructure.

COURSE OBJECTIVES:

AFTER COMPLETION OF THIS COURSE, THE PARTICIPANTS WILL BE ABLE TO:

• Define the core elements of a Mechanical Integrity (MI) program per API and ASME standards.
• Conduct comprehensive MI audits of pressure vessels, piping, and storage tanks.
• Verify compliance with API 510, API 570, and API 653 inspection codes.
• Audit the quality and accuracy of NDT data and technician certifications.
• Evaluate the effectiveness of Risk-Based Inspection (RBI) implementations.
• Verify that Fitness-for-Service (FFS) assessments are performed by competent personnel.
• Audit the "Management of Change" (MOC) process for mechanical and process shifts.
• Identify gaps in the Asset Master Record and equipment documentation systems.
• Verify that repair activities comply with ASME PCC-2 and relevant construction codes.
• Lead a multidisciplinary audit team through a structured MI verification process.
• Prepare professional audit reports with prioritized findings and recommendations.
• Develop a sustainable compliance roadmap to close identified MI gaps.

TARGET AUDIENCE:

This course is designed for MI Managers, Lead Inspectors, Quality Assurance Professionals, Asset Integrity Engineers, and Regulatory Compliance Officers. It is also highly beneficial for Plant Managers and Maintenance Directors who are responsible for ensuring that their facilities pass third-party audits and maintain their "License to Operate" through demonstrated compliance with industry standards.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.